Manual Transaxle Unit: Reassembly

INSTALL OUTPUT SHAFT COVER
1. Coat the output shaft cover with MP grease, and install it to the front transaxle case.
  NOTE: Install the output shaft cover projection into the case hole.
INSTALL OUTPUT SHAFT FRONT BEARING
1. Coat a new front bearing with gear oil.
2. Using SST and a press, press it into the front transaxle case.
  SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
  NOTE:
  - Be sure to install the bearing in the correct direction, as shown in the illustration.
  - When replacing the output shaft front bearing, also replace the front bearing inner race.
    
    Fig 1: Installing Output Shaft Front Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, press in a new front transaxle case oil seal to the front transaxle case.
  SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
  
  Standard depth: 15.6 to 16.0 mm (0.6141 to 0.6299 in.)
2. Coat the lip of the front transaxle case oil seal with MP grease.
  
  Fig 2: Installing Front Transaxle Case Oil Seal To Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT FRONT BEARING
1. Coat a new input shaft front bearing with gear oil.
2. Using SST and a press, press it into the front transaxle case.
  SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
  
  Standard depth: 0 to 0.3 mm (0 to 0.0118 in.)
  
  Fig 3: Installing Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT BIMETAL FORMED BUSH
1. Using SST and a press, press in a new bush to the transmission case.
  SST 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Standard depth: 0 to 0.5 mm (0 to 0.020 in.)
  
  Fig 4: Installing Bush To Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press in the front tapered roller bearing (inner race) to the front differential case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
  
  Fig 5: Installing Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the front tapered roller bearing (outer race) with plate washer to the front transaxle case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 6: Installing Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, press in the rear tapered roller bearing (inner race) to the differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 7: Installing Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the rear tapered roller bearing (outer race) with plate washer to the transmission case.
  SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  HINT:
  
  Use a plate washer with the same thickness as the removed one.
  
  Fig 8: Installing Rear Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Coat the differential case with gear oil, and install it to the front transaxle case.
Install the transmission case with the 16 bolts.
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)

Fig 9: Adjusting Differential Side Bearing Preload
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a torque wrench, turn the differential case to the right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011

Using SST and a torque wrench, measure the preload.

Fig 10: Measuring Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard preload (at starting)

PRELOAD SPECIFICATION

Item	specified Condition
New bearing	0.78 to 1.57 Nm (7.95 to 16.0 kgfcm, 6.9 to 13.89 in.*lbf)
Reused bearing	0.49 to 0.98 Nm (5.0 to 10.0 kgfcm, 4.34 to 8.67 in.*lbf)

If the preload is not within the specification, select another plate washer.

Standard plate washer thickness

PLATE WASHER SPECIFICATION

Mark	Thickness mm (in.)
AA	2.10 (0.0827)
BB	2.15 (0.0846)
CC	2.20 (0.0866)
DD	2.25 (0.0886)
EE	2.30 (0.0906)
FF	2.35 (0.0925)
GG	2.40 (0.0945)
HH	2.45 (0.0965)
JJ	2.50 (0.0984)
KK	2.55 (0.1004)
LL	2.60 (0.1024)
MM	2.65 (0.1043)
NN	2.70 (0.1063)
PP	2.75 (0.1083)
QQ	2.80 (0.1102)
RR	2.85 (0.1122)
SS	2.90 (0.1142)
TT	2.95 (0.1161)
UU	3.00 (0.1181)

HINT:

The preload will change by about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) corresponding to a change of 0.05 mm (0.0020 in.) in plate washer thickness.

Remove the 16 bolts and transmission case.
Remove the differential case from the front transaxle case.

INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, tap in a new transmission case oil seal to the transmission case.
  SST 09316-60011 (09316-00011)
  
  Standard drive depth: 2.1 to 2.7 mm (0.082677 to 0.106299 in.)
2. Coat the lip of the front transmission case oil seal with MP grease.
  
  Fig 11: Installing Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, tap in a new oil seal to the front transaxle case.
  SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
  
  Standard depth: 1.6 to 2.2 mm (0.0629 to 0.0866 in.)
2. Coat the lip of the oil seal with MP grease.
  
  Fig 12: Tapping In Oil Seal To Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet, and install it to the front transaxle case.
  
  Fig 13: Installing Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING LOCK PLATE
1. Install the bearing lock plate to the front transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
  
  Fig 14: Installing Bearing Lock Plate To Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL RECEIVER PIPE
1. Install the No. 1 oil receiver pipe to the transmission case with the bolt.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  NOTE:
  - Prevent the No. 1 oil receiver pipe from being deformed.
  - Install the No. 1 oil receiver pipe while placing it against the transmission case, as shown in the illustration.
    
    Fig 15: Installing No. 1 Oil Receiver Pipe To Transmission Case
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL RECEIVER PIPE
1. Install the No. 2 oil receiver pipe to the transmission case with the bolt.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  NOTE:
  - Prevent the No. 2 oil receiver pipe from being deformed.
  - Install the No. 2 oil receiver pipe while placing it against the transmission case, as shown in the illustration.
    
    Fig 16: Installing No. 2 Oil Receiver Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE RESTRICT PIN ASSEMBLY
1. Install the reverse restrict pin to the manual transmission case.
  NOTE: Be sure to set the reverse restrict pin in the correct orientation.
  
  Fig 17: Installing Reverse Restrict Pin To Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 5 mm pin punch and hammer, tap in the slotted pin to the reverse restrict pin.
  Standard depth: 16.0 to 17.0 mm (0.6299 to 0.6693 in.)
  
  Fig 18: Tapping In Slotted Pin To Reverse Restrict Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply sealant to the reverse restrict pin plug.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Using a hexagon wrench and torque wrench, install the reverse restrict pin plug to the transmission case.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 19: Installing Reverse Restrict Pin Plug To Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE CASE RECEIVER
1. Install the transaxle case receiver to the front transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
  
  Fig 20: Installing Transaxle Case Receiver To Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CASE ASSEMBLY
1. Coat the differential case tapered roller bearing with gear oil, and install the differential case to the front transaxle case.
  
  Fig 21: Installing Differential Case To Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
1. Coat the sliding and rotating surface of the input and output shafts with gear oil, and install them to the transaxle case.
  
  Fig 22: Installing Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
1. Coat the reverse idler gear, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
  HINT:
  
  Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the illustration.
  
  Fig 23: Installing Reverse Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GEAR SHIFT FORK SHAFT
1. Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil, and install them.
  
  Fig 24: Installing No. 1 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the No. 1 gear shift fork shaft with gear oil, and install it.
3. Apply sealant to the shift fork set bolt.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the shift fork set bolt.
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 25: Installing No. 1 Gear Shift Fork And No. 2 Gear Shift Fork With Gear Oil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and hammer, tap in a new shaft snap ring to the No. 1 gear shift fork shaft.
  
  Fig 26: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 GEAR SHIFT FORK SHAFT
1. Coat the 2 shift fork balls with MP grease, and install them to the reverse shift fork.
2. Install the reverse shift fork to the No. 3 gear shift fork shaft.
  
  Fig 27: Installing Reverse Shift Fork To No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, tap in 2 new shift fork shaft shaft snap rings to the No. 3 shift fork shaft.
  
  Fig 28: Installing Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the No. 3 gear shift fork shaft with gear oil, and install it.
  
  Fig 29: Installing No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 GEAR SHIFT FORK SHAFT

Fig 30: Installing No. 2 Gear Shift Fork Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil, and install them.
  NOTE: To avoid the interference of the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.
  
  Fig 31: Inspecting No. 2 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift lock bolts with sealant, and install them to the No. 2 gear shift fork and No. 1 shift head.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 32: Installing Shift Lock Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Install the reverse shift arm bracket to the front transaxle case with 2 bolts.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  
  Fig 33: Installing Reverse Shift Arm Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE
1. Apply FIPG to the transmission case, as shown in the illustration.
  FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 34: Applying FIPG To Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 13 bolts with sealant, and install them to the transmission case.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 35: Installing Transmission Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 3 bolts with sealant, and install them to the front transaxle case.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 36: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SHAFT BOLT
1. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 37: Installing Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 LOCK BALL ASSEMBLY
1. Coat the No. 2 lock ball with sealant, and install it with a hexagon wrench.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 38: Installing No. 2 Lock Ball Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT DETENT BALL
1. Install the 2 shift detent balls, 2 shift detent ball springs with 2 No. 1 shift detent ball spring seats to the manual transmission case.
  
  Fig 39: Installing Shift Detent Balls And Shift Detent Ball Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant, and install them with a hexagon wrench.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 40: Installing Shift Detent Ball Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift detent ball, shift detent ball compression spring and No. 1 shift detent ball spring seat to the front transaxle case.
  
  Fig 41: Installing Shift Detent Ball And Shift Detent Ball Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the shift detent ball plug with sealant, and install it with a hexagon wrench.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 42: Installing Shift Detent Ball Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the hole snap ring to the input shaft.
  
  Fig 43: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the hole snap ring to the output shaft.
  
  Fig 44: Installing Snap Ring To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
1. Using a brass bar and hammer, tap in a new shift fork shaft shaft snap ring to the No. 2 shift fork shaft.
  
  Fig 45: Installing Shift Fork Shaft Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR BEARING RETAINER
1. Coat the 5 bolts with sealant, and install the rear bearing retainer to the transmission case with the 5 bolts.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 27 N*m (280 kgf*cm, 20 ft.*lbf)
  
  Fig 46: Installing Rear Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH DRIVEN GEAR
1. Using SST, install the 5th driven gear to the output shaft.
  SST 09309-12020
  
  Fig 47: Installing 5th Driven Gear To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them to the input shaft.
  
  Fig 48: Installing 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil, and install it to the input shaft.
  
  Fig 49: Installing 5th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 SYNCHRONIZER RING
1. Coat the No. 3 synchronizer ring with gear oil, and install it to the 5th gear.
  
  Fig 50: Removing No. 3 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 TRANSMISSION CLUTCH HUB

Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the No. 3 transmission clutch hub as shown in the illustration.
NOTE: Do not set both openings of the shifting key springs in the same position.

Fig 51: Installing Synchromesh Shifting Keys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a hammer, tap in the No. 3 clutch hub to the input shaft.
SST 09636-20010
NOTE:
- Do not install the No. 3 transmission clutch hub with it facing in the wrong direction.
- Install the No. 3 transmission clutch hub checking the positions of the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key.
- Check that the 5th gear is rotating.
- Place a suitable sized wooden block to support the input shaft.
  
  Fig 52: Installing No. 3 Clutch Hub To Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a No. 3 clutch hub shaft snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less

Standard snap ring thickness

SNAP RING SPECIFICATION

Mark	Thickness mm (in.)
A	2.25 (0.0886)
B	2.31 (0.0909)
C	2.37 (0.0933)
D	2.43 (0.0957)
E	2.49 (0.0980)
F	2.55 (0.1004)
G	2.61 (0.1028)

Using a brass bar and hammer, tap the snap ring onto the input shaft.

Fig 53: Installing Snap Ring Onto Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance.
  Standard clearance: 0.1 to 0.57 mm (0.0039 to 0.02244 in.)
  
  Maximum clearance: 0.57 mm (0.02244 in.)
  
  If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.
  
  Fig 54: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance

STANDARD CLEARANCE

Item	Specified Condition
KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance

MAXIMUM CLEARANCE

Item	Specified Condition
KOYO made	0.058 mm (0.0023 in.)
NSK made	0.056 mm (0.0022 in.)

If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.

Fig 55: Measuring Radial Clearance

INSTALL NO. 3 GEAR SHIFT FORK
1. Coat the No. 3 transmission clutch hub sleeve with gear oil, and install it and the No. 3 gear shift fork to the No. 3 transmission clutch hub.
  HINT:
  
  Be sure to set the No. 3 transmission clutch hub in the correct orientation.
  
  Fig 56: Installing No. 3 Gear Shift Fork To No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork lock bolt with sealant, and install it to the No. 3 gear shift fork.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 57: Installing Gear Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Engage the 2 gears simultaneously to lock the transmission.
2. Install a new set nut.
  Torque: 118 N*m (1200 kgf*cm, 87 ft.*lbf)
  
  Fig 58: Installing Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and hammer, stake the set nut.
4. Disengage the 2 gears.
  
  Fig 59: Staking Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Apply FIPG to the transaxle case cover as shown in the illustration.
  FIPG: Part No. 08826-00090, THREE BOND 1281
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 60: Applying FIPG To Transaxle Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transmission case cover to the transmission case with the 9 bolts.
  Torque: 18 N*m (185 kgf*cm, 14 ft.*lbf)
  
  Fig 61: Installing Transmission Case Cover To Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Coat the 4 bolts with sealant and install a new gasket and lever shaft to the transmission case with the 4 bolts.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  
  NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
  
  Fig 62: Installing Shift And Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 LOCK BALL ASSEMBLY
1. Coat the No. 1 lock ball with sealant, and install it to the transmission case.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 63: Installing No. 1 Lock Ball Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELECTING BELLCRANK ASSEMBLY
1. Install the selecting bellcrank with control shift lever bush to the transmission case with the 2 bolts.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
  
  Fig 64: Installing Selecting Bellcrank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Install the floor shift control lever housing support bracket to the front transaxle case with the 3 bolts.
  Torque: 18 N*m (188 kgf*cm, 14 ft.*lbf)
  
  Fig 65: Installing Floor Shift Control Lever Housing Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back-up light switch to the transmission case with a new gasket.
  SST 09817-16011
  
  Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf)
  
  Fig 66: Installing Back-Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support to the front transaxle case.
  Torque: 37 N*m (375 kgf*cm, 25 ft.*lbf)
  
  Fig 67: Installing Release Fork Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK BOOT
1. Install the clutch release fork boot to the front transaxle case.
  
  Fig 68: Installing Clutch Release Fork Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE BEARING ASSEMBLY
1. Coat the clutch release bearing with release hub grease, and install it to the clutch release fork with the clutch release fork bearing hub clip.
  Release hub grease: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
  
  Fig 69: Installing Clutch Release Bearing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Install the clutch release fork to the input shaft.
2. Apply clutch spline grease to the spline of the input shaft.
  Clutch spline grease: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
  
  Fig 70: Installing Clutch Release Fork Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Install a new O-ring to the driven hole cover.
2. Install the driven hole cover to the transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
1. Install the clutch release cylinder to the transmission case with the 2 bolts.
  Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf)
  
  Fig 71: Installing Clutch Release Cylinder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION FILLER PLUG
1. Install the transmission filler plug to the transmission case with a new gasket.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 72: Installing Manual Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG SUB-ASSEMBLY
1. Install the drain plug to the transmission case with a new gasket.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 73: Installing Drain Plug Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002